Padded articles and method of making them



1962 G. E. WINTERMUTE ETAL 3,022,211

PADDED ARTICLES AND METHOD OF MAKING THEM Filed April 17, 1957 IN V EN TORS By James Kfimmw and .TOH N 6555167! m/v,

HTTOP/YYS.

- structural member.

United States PatentOfiice 3,022,211 'Patented Feb. 20, 1962 Brighton, Columbus, Ind., assignors to Arvin Industn'es, Inc., Columbus, Ind., a corporation of Indiana Filed Apr. 17, 1957, Ser. No. 653,402 9 Claims. 01. 156-222) This invention relates to a method of making articles embodying foam-elastomer pads and is principally concerned with, although not limited to, the production of an article comprising a sheet-metal or other relatively rigid structural member, a foam-elastomer pad thereon, and a skin of flexible sheet material covering the pad and The method is well suited for the production of articles, such as card-table tops, chair-seats,

' and chair backs, where the pad has a considerable extent and may be of generally uniform thickness throughout at least the major portion of that extent.

The principal feature characterizing our invention is the steps of compressing a foam-elastomer pad of opencell structure between two sheets of material the marginal portions of which extend outwardly beyond the pad, and

'bonding such margin-alsheet-portions together to form a seal preventing air from re-entering the pad. In this mannet, the pad is held compressed by atmospheric pressure until, at a later time, air is admitted to the pad to relieve the vacuum and permit the pad to expand as limited by tension in the enclosing sheets. If one or both of the enclosing sheets -is of flexible, stretchable material, 'air can be readmitted to the pad by pricking small holes'in such material within the peripheral limits of the pad. If

,one of the enclosing sheets is. of rigid material, such sheet .may be drilled to provide an air-admitting opening or openings.

According to the preferred mode of practicing the invention, where one of the pad enclosing sheets is of metal .we form a laminated panel by interposing a foam-elastomer pad precut to the desired size and shape between a .sheet of metal and a sheet of the flexible material which is to constitute the skin. The foam-elastomer of which the pad is formed is of the open-cell type. the flexible material is impervious to air, and both the flexible material and the sheet-metal extend beyond the margins of the pad.

'the pad is thus compressed, the marginal portions of the skin and sheet-metal beyond the periphery of the pad are bonded together to effect an air-tight seal preventing readmission of air to the pad-cells whenthe pressure is released. The pad is desirably bonded to the metal panel,

and may alsobe bonded to the skin. With the air expelled from and prevented from re-entering the pad, the pad remains compressed by atmospheric pressure, and the laminated panel may be formed to any desired contour. After any such forming operation, air is reintroduced into said pad by perforaing the skin or the metal panel, thus permitting the pad to expand and form a resilient cushion integrally bonded between said skin and metal and conforming to the configuration of said metal. In quantity production, continuous strips of sheet-metal and skin material may be bonded together with compressed pads interposed between them at appropriate intervals and the extended laminated structure thus produced cut up into of producing a continuous laminated sheet which can be" cut into sections to provide the laminated panels above described;

FIG. 2 is a fragmental isometric view, in partial section, illustrating one of our laminated panels after it has been formed into a flanged table-top, the figure showing the pad as still compressed;

FIG. 3 is a fragmentary isometric view similar to FIG. 2 but showing the pad expanded;

FIG. 4 is a transverse vertical section through a chairseat; and

FIG. 5 is a sectional view showing apparatus which can be employed to expand the pad beyond its original thickness.

The table-top of the drawing is shown merely to illustrate one use for our invention. 'In such embodiment a metal panel 10, which forms the basic structural member of said top, is provided with a peripheral flange 11, a foam-elastomer pad 12 covers the top and extends downwardly over the flange 11, and a flexible skin 14 covers the pad and is bonded to the flange 11 below the margins of the pad.

In forming laminated padded articles in quantity production, it is convenient to laminate continuous strips of metal and the plastic skin with the pads interposed and spaced from each other, so that by cutting between the pads the continuous structure may be divided into individual panels. Such an operation is shown in FIG. 1,

hesive is a thermoplastic resin, such as a polymer of polyvinylchloride. After the adhesive is applied to the metal strip said strip is passed through an oven 17 which heats the strip and adhesive to a temperamre, say in the range of 375 F .400 F., to soften and condition the adhesive for bonding the pads and skin to the metal.

Foam-elastomer pads 12 cut to the desired size and shape are shown as cemented on one face of a continuous strip 19 of the skin-forming material and the two continuous strips, with the pads 12 between them, are brought together and passed between pressure rolls 20. The rollers 2i) bring the superimposed panel components into intimate contact, with the softened adhesive 16 bonding the pads 12 to the metal and also providing a bond between those portions of the skin and metal strip extending between and laterally beyond the pads 12. During this bonding operation, the rollers 20 also expel all of the air from the pads 12, compressing them into substantially solid nonresilient masses having only a fraction of their original thickness and disposed within a border defined by the lamination bond between the contacting portions of the panel and skin. After passing through the rollers 20, the skin covered padded strip is cooled with water sprays 21, or any other suitable means to set the bonds of the laminate. The pads 12 are thereafter held compressed by atmospheric pressure.

The elongated laminated strip having the spaced, compressed pads 12 embodied therein is then out between the pads into panels of the desired shape, each such panel having a pad or pads. It is to be understood, of course,

that the panels can be produced on an individual unit basis, rather than by cutting a continuous laminated strip within the area covered by the pad, the compressed pad 12 does notinterfere with the action of the forming dies its original thickness.

and easily assumes the shape of said panel. Where it is heating the article to soften the skin and promote expandesired to bend the panel around a sharp angle, as at, the

margins of the flange 11 shown in FIGS. 2 and 3, the skin 14 may be heated prior to such bendingtomake it more pliable and soft. I

After the panel has been formed to the desired shape, air is readmitted to the pad 12, whereupon it reassumes its original resilient spongy state-and substantially regains This reinflation may be accomplished by pricking a minute hole 24, or a plurality of such holes, in the skin 14, the air entering said pad and filling the voids between the cellular elastomer structure. Al-

"te'rnatively, the air may be readmitted to said pad by drilling a plurality of holes in the panel10, thus exposing areas of said'pad to the; air so that the air mayenter the voids between the cellular walls of the elastomer.

bends created during the forming operation, the resultant tension in the skin may result in maintaining the pad compressed to an objectionable degree at the bend even .after air has been readmitted to the pad. Such undesirable compression of the pad can usually be removed by heating the skin adjacent the bend, thus softening it and allowing it to stretch to permit the pad to expand in thickness under the influence of its inherent elasticity.

While, as noted above, tension in the skin where it passes over the outside of a bend inthe metal panel tends to compress the pad, the reverse eflEect exists where the skin is at the inside of a bend in the panel; for the formation of such a bend permits more expansion of the pad than would otherwise occur. Bending the panel in such manner to increase expansion of the pad maybe desirable in such articles as chair-seats, chair-backs, where maximum thickness of the pad is desired. A chair-seat so constructed is shown in FIG. 4, where, prior to reinflation of the pad, a plane laminated panel is subjected to forming operations dishing its central portion 25 and providing a down-turnedperipheral flange 26. Over thedished portion 25, the reinflated pad can expand without increasing tension in the skin, and the pad is therefore thicker at its center than at its edges where it and the skinlie on the outside of thebend. I

In practicing the invention in the manner specifically described above, the pad will be bonded to both the metal panel and the skin, Such double bonding of the pad is especially desirable-where the panel is to be so formed that the pad and skin lie on the inside of a bend, as other- 'wise tension in the skin might create undesirable voids and 'cause the skin and the pad to depart objectionably from conformity with the shape of the panel. A bond between V the pad and panel is desirable to locate the pad in definite position on the panel independently of the skin; but in many instances, especially where the skin passes over the outside of a bend, the bond between the skin and pad may be eliminated. e

The invention is not limited to the production of furniture parts or other articles where the pad is to serve as a cushion; as the laminated panel, with the pad reinflated, possesses desirable heat insulating and acoustical properties adapting it for other uses. Although the possibility of maintaining the pad compressed with the aid of atmospheric pressure has great value Where one of the padenclosing elements is a metal sheet which is to be formed between the marginal portions of the enclosing sheets is J not stressed by elastic pad-expanding forces, and it is un- V necessary to maintain the bonded sheet-edges under pressure until the bond has completely set. Again, with the pad compressed the thickness of the laminate is much less than it would otherwise be, and the resulting compactness sion of the pad after air has been admitted to its cells. In certain instances, it may be that a mere softening of the skin will not in itself result in adequate expansion of the pad; and in such instances, the procedure illustrated in FIG. 5 may be followed. As, there shown, the laminated panel comprising a sheet-metal base 30, a foamelastomer pad 31, and a flexible skin 32 covering the pad has been formed in the manner above describedland, prior to reinflation of the pad, has been rather deeply drawn into a general dome-like shape with accompanying stretching of the skin 32. lt'is assumed, in FIG. 5, that the pad 31 has been'reinflated, by providing holes 33 in the base 31, but that the reinfiation of the pad'has not increased its thickness to the extent desired. In such an instance, the article may be placed in a die 35 having a die-cavity 36 corresponding in shape to the desired outer conformation of the article over the pad. The die is provided with passages 37 permitting escape of air from the cavity 36 and with heating elements 38 through'which the temperature of the article may be raised. By heating the die to soften the skin 32 and the elastomer of the pad, and by forcing air into the pad through the openings 33, the pad can be expanded until the skin 32 is brought into contact with the wall of cavity 36; and if the die is then cooled while pressure is maintained in the pad, the pad :will retain its increased thickness. To introduce air in the pad, the interior of the article may be closedby a'plate 40 arranged in sealing relation with'the peripheral portions of the article and air under pressure supplied through a conduit 41. Alternatively, the die-cavity might be exhausted through the passages 37 to permit air at atmospheric pressure to enter the openings 33 and expand the pad; or, if desired, the pad could be expanded by the joint elfectof vacuum in the cavity 36 and of pressurized air supplied through the openings 33.- V

The term foam-elastomer as usedherein includes all forms of cellular resilient material, such as vinyl foam, foam rubber, sponge rubber, urethane foam and the like.

We claim as our invention:

1. A method of making a padded article, comprising interposing -a foam-'elastomer padbetween a sheet of rigid material and a sheet of flexible, stretchable material, the marginal portions of both sheets extending beyond the edges of the pad, forcing said two sheets toward each other to expel air from and compress the pad, bonding the padsurrounding marginal portions of the sheets together simultaneously with the step of compressing the pad to prevent air from re-entering the pad, and subsequently is an advantage in storage, handling, assembly and ship- I merit.

Reference has been made above to the possibility of perforating one of said sheets within the limits of the pad to permit air to enter the pad.

2. A method as set forth in claim 1 wherein it is the flexible sheet that is perforated.

3. A method as set forth" claim 1 wherein, after the compressing and bonding steps and before the perforating step, the rigid sheet is subjected to a forming operation changing its shape.

* 4. A method as setforth in claim 1 with the additional steps of bonding the pad to the rigid sheet and to the flexible sheet, and subjecting said rigidsheet to a forming operation to change its shape subsequent to said compressing and bonding steps and before the perforating step, the forming operation creating in the rigid sheet a bend which is concave on the side covered by the pad.

5. A method as set forth in claim 1 with the additional step of bonding the pad to the rigid sheet and to the flexible sheet simultaneously with the step of bonding the marginal portions of the sheets together.

6. A method as set forth in claim 1 with the additional step of bonding the pad to the rigid sheet simultaneously with the step of bonding the marginal portions of the sheets together.

7. A method of making padded articles, comprising interposing foam-elastomer pads in spaced relation between a continuous sheet of metal and a continuous sheet of flexible, stretchable material, passing said sheets with the interposed pads between rolls to expel air from and compress the pads and, with the aid of pressure exerted by the rolls, bonding the two sheets together beyond the edges of each pad simultaneously with the successive compression of the pads to prevent air from re-entering the pads, and form a compact laminate, cutting said laminate into sections each including one of said pads, and readmitting air to said pads to permit their expansion.

8. A method as set forth in claim 7 with the addition that the readmitting of air is effected by perforating the flexible material within the borders of the pad.

9. A method of making a padded article, comprising interposing a foam-elastomer pad between two sheets of material at least one of which is flexible and stretchable, the marginal portions of both sheets extending beyond the edges of the pad, forcing said two sheets toward each other to expel air from and compress the pad, bonding the pad-surrounding marginal portions of the sheets together simultaneously with the step by compressing the pad to prevent air from re-entering the pad, whereby atmospheric pressure will hold the pad compressed, and subsequently readmitting air to the pad to permit it to expand.

References Cited in the file of this patent UNITED STATES PATENTS 2,232,783 Hausheer Feb. 25, 1941 2,314,046 Kalter Mar. 16, 1943 2,649,900 Pfankuch Aug. 25, 1953 2,713,892 Knapp July 26, 1955 2,723,666 Greenberg Nov. 15, 1955 2,771,612 Samuels Nov. 27, 1956 2,801,199 Meyers July 30, 1957 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,022,211 February 2O 1962 Glenn E. Wintermute et a1.

It is hereby certified that error appears in the above numbered patent requiring correction and that the said Letters Patent should read as corrected below.

Column l llne 43, for "type." read type line 59, for "perforalng" read perforating column 3, line 11, for "14," read 14; column 6, line 3, for "by" read of Signed and sealed this 31st day of July 1962,

(SEAL) Attest:

ERNEST w. SWIDER DAVID LADD Attesting Officer Commissioner of Patents 

1. A METHOD OF MAKING A PADDED ARTICLE, COMPRISING INTERPOSING A FOAM-ELASTOMER PAD BETWEEN A SHEET OF RIGID MATERIAL AND A SHEET OF FLEXIBLE, STRETCHABLE MATERIAL, THE MARGINAL PORTIONS OF BOTH SHEETS EXTENDING BEYOND THE EDGES OF THE PAD, FORCING SAID TWO SHEETS TOWARD EACH OTHER TO EXPEL AIR FROM AND COMPRESS THE PAD, BONDING THE PAD-SURROUNDING MARGINAL PORTIONS OF THE SHEETS TOGETHER SIMULTANEOUSLY WITH THE STEP OF COMPRESSING THE PAD TO PREVENT AIR FROM RE-ENTERING THE PAD, AND SUBSEQUENTLY PERFORATING ONE OF SAID SHEETS WITHIN THE LIMITS OF THE PAD TO PERMIT AIR TO ENTER THE PAD. 